Composite package and method of forming same

ABSTRACT

A composite package having three separably connected containers. The containers are initially formed integrally as receptacles in a base sheet of a self-supporting plastic material, each receptacle being open at its upper end and closed at the bottom. A cover sheet is bonded to the upper face of the base sheet to overlie the open ends of the receptacles. The cover sheet is formed with small product dispensing apertures which register with the open ends of two of the receptacles. The cover sheet completely overlies the open end of the third receptacle. A top sheet is applied over the cover sheet to complete the containers. The cover sheet is peelable from the base sheet and the top sheet is more easily peelable from the cover sheet. The three sheets are severed in a predetermined manner and along predetermined lines to facilitate separation of the containers from one another and to provide lift tabs facilitating peeling the sheets from one another when it is desired to dispense the product. The receptacles are filled with a product through the open upper ends thereof before the cover sheet is applied thereto. In one form of the invention the top sheet overlies only the receptacle where the cover sheet is provided with the small dispensing openings.

United States Patent v Chung, Yun Hoon 51 Mar. 21, 19 72 54] COMPOSITE PACKAGE AND METHOD OF FORMING SAME [72] lnventor: Chung, Yun Hoon, Perrysburg, Ohio International Automated Machines, lnc., Perrysburg, Ohio [22] Filed: Aug. 14, 1970 [21] Appl.No.: 63,690

[73] Assignee:

[52] U.S. Cl ..206/56 AA, 206/47 R, 229/51 D,

Primary Examiner-William T. Dixson, Jr. 5 Assistant Examiner-Steven E. Lipman Attorney-Bames, Kisselle, Raisch & Choate [57] ABSTRACT A composite package having three separably connected containers. The containers are initially formed integrally as receptacles in a base sheet of a self-supporting plastic material, each receptacle being open at its upper end and closed at the bottom. A cover sheet is bonded to the upper face of the base sheet to overlie the open ends of the receptacles. The cover sheet is formed with small product dispensing apertures which register with the open ends of two of the'receptacles. The cover sheet completely overlies the open end of the third receptacle. A top sheet is applied over the cover sheet to complete the containers. The cover sheet is peelable from the base sheet and the top sheet is more easily peelable from the cover sheet. The three sheets are severed in a predetermined manner and along predetermined lines to facilitate separation of the containers from one another and toprovide lift tabs facilitating peeling the sheets from one another when it is desired to dispense the product. The receptacles are filled with a product through the open upper ends thereof before the cover sheet is applied thereto. In one form of the invention the top sheet overlies only the receptacle where the cover sheet is provided with the small dispensing openings.

6 Claims, 14 Drawing Figures Patented March 21, 1972 3,650,390

Q I 2 Sheets-Sheet 1 INVENTOR YUN HOON CHUNG FIG. 1 BY 76 W M? @Amifi/ ATTORNEYS Patented March 21, 1972 2 Sheets-Sheet l INVENTOR YUN HOON CHUNG ATTORNEYS COMPOSITE PACKAGE AND METHOD OF FORMING SAME This invention relates to packages, particularly composite packages, which comprise a plurality of separable containers from which products (such as salt, pepper, sugar, ketchup, etc.) are adapted to be dispensed and to the method of forming such packages.

More specifically, the invention encompasses a simple and inexpensive composite package consisting of several separably connected containers filled with food or other products which may be related in use or for some other reason. (Food products, for example, such as: salt, pepper and ketchup; sugar, cream and sugar substitute; etc.) Composite packages of this type are admirably suited for institutional use such as in hospitals or on airlines or in cafeterias where packages of such related food products are frequently served.

It is an object of this invention to provide a composite package which is of simple and attractive design, which can be manufactured economically, and which is constructed so that from the functional standpoint the containers can be separated from one another and the product dispensed therefrom very conveniently.

A further object of the invention resides in the provision of a method of forming such composite packages which lends itself to low cost, high speed production.

Other objects and features of the present invention will become apparent from the following description and drawings, in which:

FIG. 1 is a plan view showing the progressive steps employed in forming the composite package of the present inventron.

FIG. 2 is a plan view of the completely formed package.

FIG. 3 is a plan view of one of the containers of the composite package separated from the remaining containers.

FIG. 3A is a perspective view showing the manner in which the top sheet on one container is removed for dispensing product.

FIG. 4 is a view similar to FIG. 3 and showing the container in condition ready for dispensing the product.

FIG. 5 is a plan view of another of the containers shown in FIG. 2 with the top sheet removed therefrom so as to permit dispensing of product.

FIG. 6 is a sectional view along line VIVI in FIG. 2.

FIG. 7 is a view similar to FIG. 1 and showing a method of forming a modified composite package.

FIG. 8 is a plan view of the package formed in accordance with the method shown in FIG. 7.

FIG. 9 is a plan view of one of the containers of the modified form of package after the cover sheet has been removed.

FIG. 10 is a plan view of the other container of the composite package shown in FIG. 8.

FIG. 10A is a perspective view showing the manner in which the top sheet on the container shown in FIG. 10 is removed.

FIG. 11 is a plan view of the container shown in FIG. 10 in a condition ready for dispensing the product.

FIG. 12 is a sectional view along line XIIXII in FIG. 8.

Referring to FIGS. 1 through 6, the composite package of the present invention, generally designated 10, and the method of forming such package are illustrated. Package 10, generally speaking, comprises three individual containers such as two generally cylindrical salt and pepper shakers l2 and 14 and a container 16 for sugar, ketchup, mustard, etc. Containers l2 and 14 are of the same shape and include a cylindrical side wall 18, a bottom wall 20 and an outwardly extending peripheral lip 22 around the upper open end thereof. Container 16 is generally rectangularly shaped and provided with a side wall 24, a bottom wall 28 and a peripheral lip 30 around the upper open end thereof.

The manner in which the composite package 10 is formed is generally illustrated in FIG. 1 which shows the progressive steps in the formation of the package. Initially a base sheet of plastic material 32 of suitable width and of continuous strip form is formed with cavities or pockets 34, 36 and 38. These pockets eventually form the receptacles of containers [2, l4 and 16, respectively. Base sheet 32 is formed of a self-supporting plastic material and pockets 34, 36,38 are formed therein by any suitable means, such as a vacuum forming process. The pockets are formed in base sheet 32 in groups of three as illustrated and each group of pockets is spaced from the adjacent group of pockets in a predetermined manner as illustrated in FIG. 1. Base sheet 32 is also formed with a pair of through apertures 39 associated with each group of pockets.

After the pockets are formed in base sheet 32, the sheet is advanced to a first station designated A in FIG. 1 where each of the pockets or receptacles is filled with a selected product through its open upper end. For example, receptacle 34 may be filled with salt, receptacle 36 filled with pepper, and recep tacle 38 filled with sugar, mustard, ketchup, etc.

The base sheet 32 is then advanced to a successive station B where a cover sheet 40 is applied over and bonded to base sheet 32. Cover sheet 40 may be a thin plastic film or other scalable flexible sheet material such as a plastic-coated paper and is bonded to base sheet 32 at the lip portions surrounding receptacles 34,36,38. Cover sheet 40 is bonded to base sheet 32 so as to be peelable therefrom. Cover sheet 40 is formed with two groups of small apertures 44 which register with the upper open ends of receptacles 34 and 36. Before application to base sheet 32 cover sheet 40 is also die cut along a straight line 45 which extends transversely between receptacle 38 and receptacles 34,36.

After the two sheets are slitted as indicated at 45 the bonded sheets are advanced to a successive station C where sheets 32 and 40 are die out along the angled lines 48,50. As is apparent from FIG. 1, the severing line 48 extends between receptacle 34 and receptacle 38 and is located closer to receptacle 34 than it is to receptacle 38. One end of severing line 48 intersects the straight line 45. Likewise, severing line 50 is located more closely adjacent receptacle 36 than receptacle 38 and has one end thereof intersecting straight slit 45.

After the die cutting operation at station C in FIG. 1 the composite sheet is advanced to a successive station D where a top sheet 52 is applied to cover sheet 40 and is bonded thereto. Top sheet 52 can be in the form of a thin pressure sensitive adhesive strip of paper, metal foil or plastic film, depending primarily upon the products being packaged and the manufacturer's preference. Top sheet 52 is bonded to cover sheet,40 so as to be more readily peelable therefrom than is cover sheet 40 relative to base sheet 32. Depending on the materials used for sheets 32,40,52, the peelable bonds between these sheets may be effected by either pressure sensitive adhesives, heat sealing operations, or any other suitable bonding operation. In any event, in the arrangement illustrated the bond between sheets 40 and 52 is more readily peelable than the bond between sheets 32 and 40. As shown, at station D top sheet 52 overlies the entire cover sheet 40 and thus closes openings 44. The upper end of receptacle 38 and openings 39 are closed by cover sheet 40. This is apparent from the showing at stations B and C. Prior to its application to cover sheet 40, top sheet 52 is slitted along the angular lines 54,56. As indicated at station D in FIG. 1, the slitted line 54 extends between slit 48 in cover sheet 40 and base sheet 32 and the adjacent side wall portion of receptacle 38. The angled slit 54 is dimensioned so that at one end it will extend beyond the straight slit 45 in base sheet 32 and cover sheet 40. The slitted angular line 56 is likewise disposed between slit S0 and the adjacent side wall portion of receptacle 38 and is so dimensioned in length to extend beyond straight slit 45.

The final step in the formation of the composite package is shown at the next successive station E in FIG. 1. At station E all three sheets are die cut to provide the desired outline configuration of the composite package. Thus, adjacent two corners of receptacle 38, remote from receptacles 34,36, the composite package is formed with laterally outwardly projecting lugs 58 which only partially overlie openings 39 in base sheet 32. Adjacent the lugs 58 the package is formed with inwardly recessed straight side edges 60. The edges of the composite package then extend circumferentially around the laterally outer sides of receptacles 34,36 as at 62; and at the edge of the package, opposite lugs 58, the die cut is made along a straight line as at 64 to complete the peripheral edge of the package. I

As shown in FIGS. 1 and 2, it will be observed that slits 45,48,50,54,56 extend to edge portions of the composite package. It is, therefore, apparent that container 12 is joined to container 16 between slits 48 and 54 by the bond between top sheet 52 and cover sheet 40. Likewise, container 14 is connected to container 16 between slits 50 and 56 by the bond between the cover sheet 40 and top sheet 52. The self-supporting nature of the composite package is enhanced by the fact that slits 48,50 are angled or curved (as distinguished from being straight lines) and, thus, the tendency for containers l2 and 14 to bend or sag along severing lines 48,50 is minimized.

It is contemplated that the user will receive the composite package in the form illustrated in FIG. 2 and that he will be able to selectively dispense the contents of each of the containers 12,14,16. To dispense the contents of containers 12 or 14 it is merely necessary for the user to peel these containers upwardly from the portion of the composite package defining container 12. Thus, top sheet 52 is peeled from cover sheet 40 at the portion thereof between slits 48,54 in the case of container l2 and between slits 50,56 in the case of container 14.

When either of these containers is separated from the composite package it will have the appearance shown in FIG. 3. When thus separated the portion of top sheet 52 between slits 48,54 provides a lift tab 66 which facilitates removal of top sheet 52 from the container so as to expose the dispensing apertures 44. The manner in which top sheet 52 is peeled from cover sheet 40 by means of lift tab 66 is illustrated in FIG. 3A. After the top sheet is removed from the container, the product in the container can be dispensed in a manner similar to which the ordinary salt or pepper shaker is used.

The portions of cover sheet 40 and top sheet 52 which overlie the cut outs 39 in base sheet 32 provide pull'tabs 69 for facilitating the peeling of cover sheet 40 and top sheet 52 together as a unit from base sheet 32 so as to uncover receptacle 38. Thus, if it is desired to dispense the product within container 16, the two sheets 40,52 are gripped at either of the lift tabs 69 and peeled upwardly. Both sheets peel off the lip portion 30 around receptacle 38 as a unit until the peeling action advances to the straight slit 45 in cover sheet 40. Since top sheet 52 peels more readily from cover sheet 40 than cover sheet 40 peels from base sheet 32, beyond the straight slit 45 top sheet 52 merely peels off from cover sheet 40, thus leaving the composite package intact in the event that containers 12 and 14 have not been previously separated therefrom.

Referring now to FIGS. 7 through 12, a slightly different form of composite package and the method of forming the same are illustrated. The progressive steps of the method of forming are illustrated in FIG. 7. In this form of the invention the composite package, generally designated 100, comprises a small cylindrical container 102 and a larger rectangular container 104. Container 102 is adapted to contain salt, pepper, etc., and container 104 is adapted to be filled with a product such as sugar, ketchup, mustard, etc. Container 102 has a cylindrical side wall 106, a bottom wall 108 and an outwardly extending peripheral lip 110 around the upper open end thereof. Container 104 is likewise provided with a peripheral side wall 112, a bottom wall 114 and a peripheral lip 116 around the upper open end thereof.

The manner in which composite package 100 is formed is generally illustrated in FIG. 7 which shows the progressive steps in the formation of the package. Initially the base sheet 118 of plastic material and of continuous strip form is provided with cavities of pockets 120 and 122. These pockets eventually form the receptacles of containers 102 and 104, respectively. As in the form previously described, base sheet 118 comprises a self-supporting plastic material and pockets 120,122 are formed therein by any suitable means, such as a vacuum forming process. The pockets are formed in base sheet 118 in groups of two as illustratedv and each group of pockets is spaced from the adjacent group of pockets in a predetermined manner as illustrated in FIG. 1. Base sheet 1 18 is also formed with successive through apertures 126. After the pockets 120,122 and aperture 126 are formed in base sheet 118, the sheet is advanced to a first station designated A in FIG. 7 where each of the pockets or receptacles is filled with a selected product through its open upper end.

The base sheet 118 is then advanced to a successive station B where a cover sheet 128 is applied over and bonded to base sheet 118. Cover sheet 128 may be in the form of a thin plastic film or plastic-coated paper and is bonded to base sheet 1 18 so as to be peelable therefrom. Cover sheet 128 is formed with a plurality of successively spaced openings 130 which are spaced apart lengthwise of the sheet to register with the open ends of receptacle 120. Before application to base sheet 118, cover sheet 128 is die cut along a straight line 132 which is located adjacent receptacle 122. After cover sheet 128 is bonded to base sheet 1 18 the bonded sheets are advanced to a successive station C where both sheets are die cut along an arcuate line 134. As is the case with the slit 132, slit 134 extends between receptacles 120 and 122. However, the arcuate slit 134 is located adjacent receptacle 120. If desired, the arcuate slit 134 may be made simultaneously with slit 132.

After the die cutting operations illustrated at stations B and C are completed the composite sheet is advanced to a successive station D where a top sheet 136 is applied. As shown in FIG. 7, top sheet 136 is substantially narrower than base sheet 1 1 18 and cover sheet 128. Top sheet 136 is dimensioned so that its edge 138 lies between slit 132 and slit 134. Before being applied to cover sheet 128, top sheet 136 is formed with an arcuate slit therethrough 140 which is located so as to extend between the arcuate slit 134 and the edge 138 of the strip. As in the previous embodiment described, top sheet 136 is bonded to cover sheet 128 so as to be peelable therefrom more readily than is cover sheet 128 relative to base sheet 118.

The composite sheet is then advanced to station E where the final composite package is die cut from the laminated sheets to present the form shown in FIG. 8. Thus, at station E all three sheets are die cut to provide the desired outline configuration. It will be observed that the package is shaped so that in the final die cutting operation one corner of the cover sheet 128 partially overlies opening 126 in base sheet 118 to provide a pull tab 142. It will also be noted that the outline of the die cut generally designated 144 intersects the opposite ends of slits 132, 140 and 13.4.

With the package formed as shown in FIG. 8, if it is desired to discharge the contents of receptacle 122, pull tab 142 of cover sheet 128 is lifted to peel'the cover sheet from container 100. However, this peeling action stops when it reaches slit 132 so that only receptacle 122 is uncovered (FIG. 12). If it is desired to separate containers 102 and 104, then container 102 is lifted or twisted relative to container 104 so as to peel top sheet 136 from cover sheet 128 at the portion of the latter designated 146 between the two slits 132,140. The remaining overhanging portion of top sheet 136 between lines 134,140 provides a pull tab 148 which facilitates peeling the top sheet from container 102 when it is desired to dispense the contents thereof. The manner in which the cover sheet is peeled from container 102 to expose discharge openings is shown in FIG. 10A. FIG. 9 shows container 104 separated from container 102 and with the cover sheet peeled therefrom.

It will be appreciated that in view of the nature of base sheet 32 and the receptacles formed therein the containers themselves can be manually manipulated conveniently since they are at least of a semirigid nature.

I claim:

1. A composite package having a plurality of separably connected containers comprising a base sheet having a pair of spaced apart receptacles therein which are closed at the bottom and open at the top, each receptacle having a generally flat peripheral lip portion extending around its upper end, a cover sheet overlying said base sheet and bonded to said lip portions around the periphery of each receptacle, said cover sheet having a dispensing opening therein overlying the open upper end of one of said receptacles, said dispensing opening being substantially smaller in size than the area of the open end of the receptacle which it overlies to permit controlled discharge of the contents of said one receptacle when the latter is inverted, a top sheet overlying that portion of the cover sheet which contains said discharge opening and also overlying the portion of the cover sheet extending between the two receptacles, said cover sheet being bonded to the base sheet so as to be peelable therefrom and said top sheet being bonded to the cover sheet so as to be more readilypeelable therefrom, said cover sheet being severed along a line extending between said receptacles and to two spaced apart edge portions of the package whereby, when the portion of the cover and top sheets overlying said other receptacle is peeled from the base sheet, both the cover and top sheets peel as a unit from the base sheet to said line of severing andas said peeling action is continued in the direction toward said one receptacle said cover sheet remains bonded to the base sheet.

2. A composite package as called for in claim 1 wherein said top sheet at one edge portion of the package adjacent said other receptacle extends outwardly beyond the underlying edges of the cover and base sheets to provide a pull tab for facilitating peeling said portion of the top and cover sheets from the base sheet.

3. A composite package as called for in claim 2 wherein said base and cover sheets are severed along registering lines extending between said receptacles and to at least adjacent two spaced edge portions of the package, said top sheet being severed along another line in non-registering relation to said registering lines of severing, said receptacles being connected together by the peelable bond between the top and cover sheets at the portions thereof extending between said registering lines of severing and said last-mentioned line of severing.

4. A composite package as called for in claim 3 wherein said cover sheet has an imperforate portion overlying said other receptacle.

5. A composite package as called for in claim 3 wherein the portion of the top sheet which overlies said one receptacle extends laterally toward the first-mentioned line of severing on 

1. A composite package having a plurality of separably connected containers comprising a base sheet having a pair of spaced apart receptacles therein which are closed at the bottom and open at the top, each receptacle having a generally flat peripheral lip portion extending around its upper end, a cover sheet overlying said base sheet and bonded to said lip portions around the periphery of each receptacle, said cover sheet having a dispensing opening therein overlying the open upper end of one of said receptacles, said dispensing opening being substantially smaller in size than the area of the open end of the receptacle which it overlies to permit controlled discharge of the contents of said one receptacle when the latter is inverted, a top sheet overlying that portion of the cover sheet which contains said discharge opening and also overlying the portion of the cover sheet extending between the two receptacles, said cover sheet being bonded to the base sheet so as to be peelable therefrom and said top sheet being bonded to the cover sheet so as to be more readily peelable therefrom, said cover sheet being severed along a line extending between said receptacles and to two spaced apart edge portions of the package whereby, when the portion of the cover and top sheets overlying said other receptacle is peeled from the base sheet, both the cover and top sheets peel as a unit from the base sheet to said line of severing and as said peeling action is continued in the direction toward said one receptacle said cover sheet remains bonded to the base sheet.
 2. A composite package as called for in claim 1 wherein said top sheet at one edge portion of the package adjacent said other receptacle extends outwardly beyond the underlying edges of the cover and base sheets to provide a pull tab for facilitating peeling said portion of the top and cover sheets from the base sheet.
 3. A composite package as called for in claim 2 wherein said base and cover sheets are severed along registering lines extending between said receptacles and to at least adjacent two spaced edge portions of the package, said top sheet being severed along another line in non-registering relation to said registering lines of severing, said receptacles being connected together by the peelable bond between the top and cover sheets at the portions thereof extending between said registering lines of severing and said last-mentioned line of severing.
 4. A composite package as called for in claim 3 wherein said cover sheet has an imperforate portion overlying said other receptacle.
 5. A composite package as called for in claim 3 wherein the portion of the top sheet which overlies said one receptacle extends laterally toward the first-mentioned line of severing on the cover sheet but terminates short thereof.
 6. A composite package as called for in claim 3 wherein said last-mentioned line of severing is spaced substantially throughout its entire extent from said registering lines of severing. 